Coupling arrangements and methods for attaching tools to ultrasonic surgical instruments

ABSTRACT

An ultrasonic surgical instrument that has a waveguide that protrudes distally from the handpiece and a surgical tool that is configured to be coupled to the waveguide. The waveguide may have a distal end that is sized to be inserted into a cavity in a proximal end of the surgical tool and then selectively expanded to retain the distal end within the cavity to couple the surgical tool to the waveguide.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority under35 U.S.C. §120 to U.S. patent application Ser. No. 12/469,293, entitledCOUPLING ARRANGEMENTS AND METHODS FOR ATTACHING TOOLS TO ULTRASONICSURGICAL INSTRUMENTS, filed May 20, 2009, now U.S. Patent ApplicationPublication No. 2010/0298851, the entire disclosure of which is herebyincorporated by reference herein.

FIELD OF THE INVENTION

The present invention generally relates to surgical instruments, andmore particularly, to coupling arrangements and methods for attaching asurgical tool to an ultrasonic surgical instrument.

BACKGROUND

Ultrasonic surgical instruments are used for the safe and effectivetreatment of many medical conditions. Such instruments commonly includea handpiece that is coupled to an ultrasonic signal generator. Theinstruments also include an end effector that receives the ultrasonicvibrations. Ultrasonic vibrations, when transmitted to organic tissue atsuitable energy levels and using a suitable end effector, may be used tocut, dissect, elevate, cauterize tissue or to separate muscle tissue offbone. Ultrasonic instruments utilizing solid core technology areparticularly advantageous because of the amount of ultrasonic energythat may be transmitted from the ultrasonic transducer, through awaveguide, to the surgical end effector. Such instruments may be usedfor open procedures or minimally invasive procedures, such as endoscopicor laparoscopic procedures, wherein the end effector is passed through atrocar to reach the surgical site.

Typically, ultrasonic vibration is induced in the surgical end effectorby electrically exciting a transducer supported in the handpiece. Thetransducer may be constructed of one or more piezoelectric ormagnetostrictive elements. Vibrations generated by the transducersection are transmitted to the surgical end effector via an ultrasonicwaveguide that extends from the transducer section to the surgical endeffector. The waveguides and end effectors are designed to resonate atthe same frequency as the transducer. Therefore, when an end effector isattached to a transducer, the overall system frequency is the samefrequency as the transducer itself.

Solid core ultrasonic surgical instruments may be divided into twotypes, single element end effector devices and multiple-element endeffector. Single element end effector devices include instruments suchas scalpels, and ball coagulators. The use of multiple-element endeffectors such as clamping coagulators includes a mechanism to presstissue against an ultrasonic blade. Ultrasonic clamp coagulators providean improved ultrasonic surgical instrument for cutting/coagulatingtissue, particularly loose and unsupported tissue, wherein theultrasonic blade is employed in conjunction with a clamp for applying acompressive or biasing force to the tissue, whereby faster coagulationand cutting of the tissue, with less attenuation of blade motion, areachieved. Surgical elevators are instruments used to help facilitate theelevation and removal of soft tissue during surgery. Surgical elevatorsare generally employed to separate muscle from bone. Cobb or curettetype surgical elevators and used in spine surgery, especially to assistin posterior access in removing muscle tissue from bone.

Regardless of the type of end effector employed, the end effector mustbe effectively coupled to the waveguide. In some devices, the endeffector is permanently coupled to the waveguide by, for example,welding. In other arrangements, the end effector is removably coupled tothe waveguide by a threaded arrangement. Such end effectors are oftensupplied with a torque wrench that, when properly used, is designed toensure that the end effector is attached to the waveguide by anappropriate amount of torque, while avoiding the possibility of damageor device malfunction due to the application of excessive torque to theend effector. Such wrenches may be designed to interface with a distalend or portion of the end effector. In some wrench arrangements, afterthe wrench is placed on the distal end of the end effector, theclinician applies torque to the wrench until an audible click is heardat which time the wrench may be removed from the end effector.

While the use of such torque wrenches can effectively ensure that anacoustically secure connection is established between the waveguide andthe end effector, the torque wrenches may become lost or misplacedduring the preparation of the surgical tools and the surgical suite. Inaddition, the torque wrenches are typically used to detach the endeffector from the handpiece which requires the clinician to locate thetorque wrench or other tool after the surgical procedure has beencompleted. Moreover, if the clinician fails to properly use the torquewrench, there is a risk that the connection between the end effector andthe waveguide is insufficient to transmit the desired amount of acousticmotion to the end effector for optimum results.

It would be desirable to provide an ultrasonic surgical instrument thatovercomes some of the deficiencies of the current instruments and endeffector coupling arrangements. Various embodiments of the ultrasonicsurgical instruments overcome these deficiencies.

SUMMARY

In one general aspect, the various embodiments are directed to anultrasonic surgical instrument that has a handpiece that operablysupports at least one ultrasonic transducer. The surgical instrumentincludes a surgical tool that has a proximal end with a cavity therein.A waveguide protrudes distally from the handpiece and interacts with theat least one ultrasonic transducer. The waveguide has a distal endportion that is sized to be inserted into the cavity in the proximal endof the surgical tool and selectively expanded into retaining engagementtherewith.

In accordance with other embodiments of the present invention, there isprovided an ultrasonic surgical instrument that includes a handpiecethat has a housing that operably supports at least one ultrasonictransducer therein. The ultrasonic transducers are operably coupled toan ultrasonic signal generator. A waveguide protrudes distally from thehousing and interacts with the ultrasonic transducers. The waveguide hasa selectively expandable distal end portion. An actuator rod is movablysupported within the waveguide and is movable between a first positionwherein the distal end portion is expanded and a second position whereinthe distal end portion is unexpanded. The surgical instrument furtherincludes a surgical tool that has a proximal end portion that has acavity therein for receiving the distal end portion of the waveguide

In accordance with other embodiments of the present invention there isprovided a method for removably coupling a surgical tool to a waveguideof an ultrasonic surgical instrument. In various versions, the methodincludes providing a cavity in a proximal end portion of the surgicaltool and inserting a distal end of the waveguide into the cavity. Themethod further includes expanding the distal end of the waveguide toretainingly engage at least a portion of a wall of the cavity.

BRIEF DESCRIPTION OF THE FIGURES

The novel features of the various embodiments are set forth withparticularity in the appended claims. The various embodiments, however,both as to organization and methods of operation, together with furtherobjects and advantages thereof, may best be understood by reference tothe following description, taken in conjunction with the accompanyingdrawings as follows:

FIG. 1 illustrates an ultrasonic system of various embodiments of thepresent invention;

FIG. 2 illustrates a coupling arrangement embodiment of the presentinvention for coupling a surgical tool to a waveguide of an ultrasonicsurgical instrument;

FIG. 2A illustrates another coupling arrangement embodiment of thepresent invention for coupling a surgical tool to a waveguide of anultrasonic surgical instrument;

FIG. 2B illustrates another coupling arrangement embodiment of thepresent invention for coupling a surgical tool to a waveguide of anultrasonic surgical instrument;

FIG. 3 illustrates another coupling arrangement embodiment of thepresent invention for coupling a surgical tool to a waveguide of anultrasonic surgical instrument;

FIG. 3A is another view of the coupling arrangement of FIG. 3 with aportion of the waveguide in an expanded condition;

FIG. 3B illustrates another coupling arrangement embodiment of thepresent invention for coupling a surgical tool to a waveguide of anultrasonic surgical instrument;

FIG. 4 illustrates another coupling arrangement embodiment of thepresent invention for coupling a surgical tool to a waveguide of anultrasonic surgical instrument;

FIG. 5 is another view of the coupling arrangement of FIG. 4 with aportion of the surgical tool shroud shown in cross-section and the latchmembers in unexpanded conditions;

FIG. 6 is another view of the coupling arrangement of FIG. 4 with thelatch members thereof in an expanded condition;

FIG. 7 is a side view of another handpiece embodiment of the presentinvention;

FIG. 8 is an end view of the handpiece of FIG. 7;

FIG. 9 is an end view of another surgical tool embodiment of the presentinvention;

FIG. 10 is a side view of the surgical tool of FIG. 9;

FIG. 11 illustrates another coupling arrangement embodiment of thepresent invention for coupling a surgical tool to a waveguide of anultrasonic instrument with the shroud portion of the surgical tool shownin cross-section;

FIG. 12 is another cross-sectional view of the coupling arrangement ofFIG. 11 taken along a different cutting line and showing the latchmembers thereof in an expanded condition;

FIG. 13 illustrates another coupling arrangement embodiment of thepresent invention for coupling a surgical tool to a waveguide of anultrasonic surgical instrument;

FIG. 14 illustrates one form of a power vs. time curve for the couplingarrangement embodiment depicted in FIG. 13;

FIG. 15 is a partial exploded assembly view of a handpiece and surgicaltool embodiment of the present invention with a portion of the handpieceand a portion of the surgical tool shown in cross-section;

FIG. 16 is another partial cross-sectional exploded assembly view of thehandpiece and surgical tool of FIG. 16 in a coupling orientation;

FIG. 17 another partial cross-sectional exploded assembly view of thehandpiece and surgical tool of FIGS. 15 and 16 in a coupled orientation;

FIG. 18 is a cross-sectional view of a heating and cooling unit of thecoupling arrangement embodiment depicted in FIGS. 15-17;

FIG. 19 is another cross-sectional view of the heating and cooling unitof FIG. 18 as the shroud of the surgical tool is being installedthereon;

FIG. 20 is another cross-sectional view of the heating and cooling unitof FIGS. 18 and 19 with the shroud in retaining engagement therewith;

FIG. 21 illustrates an ultrasonic system of various embodiments of thepresent invention;

FIG. 22 illustrates a coupling arrangement embodiment of the presentinvention for coupling a surgical tool to a waveguide of an ultrasonicsurgical instrument, wherein the distal end of the waveguide is inretaining engagement with the surgical tool; and

FIG. 23 illustrates the coupling arrangement embodiment depicted in FIG.22 prior to expanding the distal end of the waveguide.

DETAILED DESCRIPTION

Before explaining the various embodiments in detail, it should be notedthat the embodiments are not limited in their application or use to thedetails of construction and arrangement of parts illustrated in theaccompanying Drawings and Description. The illustrative embodiments maybe implemented or incorporated in other embodiments, variations andmodifications, and may be practiced or carried out in various ways. Forexample, the surgical instruments and surgical tool configurationsdisclosed below are illustrative only and not meant to limit the scopeor application thereof. Furthermore, unless otherwise indicated, theterms and expressions employed herein have been chosen for the purposeof describing the illustrative embodiments for the convenience of thereader and are not to limit the scope thereof.

The various embodiments relate, in general, to ultrasonic surgicalinstruments and, more particularly, to coupling arrangements forcoupling a surgical tool to the source of ultrasonic energy in suchinstruments. Examples of ultrasonic surgical instruments are disclosedin U.S. Pat. Nos. 5,322,055 and 5,954,736 and in combination withultrasonic blades and surgical instruments disclosed in U.S. Pat. Nos.6,309,400 B2, 6,278,218 B1, 6,283,981 B1, and 6,325,811 B1, for example,are incorporated herein by reference in their respective entireties.Also incorporated by reference in their respective its entireties iscommonly-owned, co-pending U.S. patent application Ser. No. 11/726,625,entitled ULTRASONIC SURGICAL INSTRUMENTS, filed on Mar. 22, 2007, nowU.S. Patent Application Publication No. 2008/0234710, as well ascommonly-owned U.S. patent application Ser. No. 12/469,308, entitledTHERMALLY-ACTIVATED COUPLING ARRANGEMENTS AND METHODS FOR ATTACHINGTOOLS TO ULTRASONIC SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2010/0298743.

FIG. 1 illustrates an ultrasonic system 10 comprising an ultrasonicsignal generator 12 with ultrasonic transducer 14, handpiece 16, andsurgical tool 100 which may be employed in accordance with variousembodiments of the present invention. Various aspects of such a systemare described in further detail in U.S. Patent Publication No. US2008/0234709 A1, the disclosure of which is herein incorporated byreference in its entirety. The ultrasonic transducer 14, which is knownas a “Langevin stack”, may generally include a transduction portion 18,a first resonator or end-bell 20, and a second resonator or fore-bell22, and ancillary components. The ultrasonic transducer 14 is preferablyan integral number of one-half system wavelengths (nλ/2). An acousticassembly 24 may include the ultrasonic transducer 14, mount 26, andvelocity transformer 28.

The distal end of end-bell 20 is connected to the proximal end oftransduction portion 18, and the proximal end of fore-bell 22 isconnected to the distal end of transduction portion 18. Fore-bell 22 andend-bell 20 have a length determined by a number of variables, includingthe thickness of the transduction portion 18, the density and modulus ofelasticity of the material used to manufacture end-bell 20 and fore-bell22, and the resonant frequency of the ultrasonic transducer 14.

The transducer may be constructed of one or more piezoelectric ormagnetostrictive elements in the instrument handpiece 16. Ultrasonicvibration is induced in the surgical tool 100 by, for example,electrically exciting a transducer which may be constructed of one ormore piezoelectric or magnetostrictive elements in the instrumenthand-piece. Vibrations generated by the transducer section aretransmitted to the surgical tool 100 via an ultrasonic waveguide 28extending from the transducer section to the surgical tool 100.

In the illustrated embodiment, the transducer is constructed withpiezoelectric elements 40. The piezoelectric elements 40 may befabricated from any suitable material, such as, for example, leadzirconate-titanate, lead meta-niobate, lead titanate, or otherpiezoelectric crystal material. Each of the positive electrodes 42,negative electrodes 44, and piezoelectric elements 40 has a boreextending through the center. The positive and negative electrodes 42and 44 are electrically coupled to wires 46 and 48, respectively. Wires46 and 48 are encased within cable 50 and electrically connectable toultrasonic signal generator 12 of ultrasonic system 10.

Ultrasonic transducer 14 of the acoustic assembly 24 converts theelectrical signal from ultrasonic signal generator 12 into mechanicalenergy that results in primarily longitudinal vibratory motion of theultrasonic transducer 14 and surgical tool 100 at ultrasonicfrequencies. A suitable generator is available as model number GEN04,from Ethicon Endo-Surgery, Inc., Cincinnati, Ohio. When the acousticassembly 24 is energized, a vibratory motion standing wave is generatedthrough the acoustic assembly 24. The amplitude of the vibratory motionat any point along the acoustic assembly 24 may depend upon the locationalong the acoustic assembly 24 at which the vibratory motion ismeasured. A minimum or zero crossing in the vibratory motion standingwave is generally referred to as a node (i.e., where motion is usuallyminimal), and an absolute value maximum or peak in the standing wave isgenerally referred to as an anti-node. The distance between an anti-nodeand its nearest node is one-quarter wavelength (λ/4).

Wires 46 and 48 transmit the electrical signal from the ultrasonicsignal generator 12 to positive electrodes 42 and negative electrodes44. The piezoelectric elements 40 are energized by an electrical signalsupplied from the ultrasonic signal generator 12 in response to a footswitch 60 to produce an acoustic standing wave in the acoustic assembly24. The electrical signal causes disturbances in the piezoelectricelements 40 in the form of repeated small displacements resulting inlarge compression forces within the material. The repeated smalldisplacements cause the piezoelectric elements 40 to expand and contractin a continuous manner along the axis of the voltage gradient, producinglongitudinal waves of ultrasonic energy. The ultrasonic energy istransmitted through the acoustic assembly 24 to the surgical tool 100.

In order for the acoustic assembly 24 to deliver energy to the surgicaltool 100, all components of acoustic assembly 24 must be acousticallycoupled to the surgical tool 100. The components of the acousticassembly 24 are preferably acoustically tuned such that the length ofany assembly is an integral number of one-half wavelengths (nλ/2), wherethe wavelength λ is the wavelength of a pre-selected or operatinglongitudinal vibration drive frequency f_(d) of the acoustic assembly24, and where n is any positive integer. It is also contemplated thatthe acoustic assembly 24 may incorporate any suitable arrangement ofacoustic elements. As the present Detailed Description proceeds, thoseof ordinary skill in the art will readily understand that the system 10described above is but one example of a myriad of ultrasonic surgicalsystems that may employ various unique and novel advantages of theembodiments of the present invention.

FIGS. 1 and 2 illustrate a coupling arrangement 110 of an embodiment ofthe present invention for coupling the surgical tool 100 to thewaveguide 28. The surgical tool 100 is illustrated as a blade that has agenerally smooth exterior surface that is well-suited for coagulationand tissue reshaping applications. However, as used herein, the term“surgical tool” may encompass any surgical end effector or tool or bladethat may be operably coupled with an ultrasonic surgical handpiece orother source of ultrasonic energy in a surgical setting and includes,but is not limited to, straight and curved blades, sharp hooks,dissecting hooks, ball coagulators, clamp coagulators, etc. Exemplaryblade configurations are described in U.S. Pat. No. 6,423,082 to Houseret al., the disclosure of which is herein incorporated by reference inits entirety. Examples of clamp coagulator arrangements are disclosed inU.S. Pat. No. 6,254,623, the disclosure of which is herein incorporatedby reference in its entirety.

In the embodiment depicted in FIGS. 1 and 2, the distal end 29 of thewaveguide 28 is configured to be coupled to a coupling portion 101which, in various embodiments, comprises a complementary-shaped cavity114 provided in the proximal end portion 112 of the surgical tool 100.For example, the distal end 29 may have a frusto-conical shaped and besized to be received within cavity 14. The waveguide 28, or at least thedistal end portion 29 of the waveguide 28 is fabricated from a firstmaterial 15 that has a first coefficient of thermal expansion (CTE1).The surgical tool 100, or at least the proximal end portion 112 of thesurgical tool 100, is fabricated from a second material 103 that has asecond coefficient of thermal expansion (CTE2) that is less than thefirst coefficient of thermal expansion. Thus:

CET2<CET1

The distal end portion 29 of the waveguide 28 is sized and shapedrelative to the cavity 114 in the proximal end portion 112 of thesurgical tool 100 such that a slip fit or an amount of clearance “C” iscreated between the distal end portion 29 of the waveguide 28 and thecavity 114 when the waveguide 28 and the surgical tool 100 are atapproximately the same temperature.

In various embodiments, the waveguide 28, or at least the distal endportion 29 of the waveguide 28, may be fabricated from, for example,aluminum which has a coefficient of thermal expansion of 13.7×10⁻⁶in/in/degree F and the proximal end portion 112 of the surgical tool 100may be fabricated from, for example, titanium which has a coefficient ofthermal expansion of 4.34×10⁻⁶ in/in/degree F. In such embodiment,clearance “C” may be approximately 0.0005 inches.

To couple the surgical tool 100 to the waveguide 28, the clinicianpositions the distal end portion 29 of the waveguide 28 into the cavity114 of the surgical tool 100 as illustrated in FIG. 2. Thermal energy(i.e., heat) is then applied to the distal end portion 29 of thewaveguide 28 to increase the outside diameter or parametrical shape ofthe distal end portion 29 through thermal expansion. Because CTE1>CTE2,the outer diameter or parametrical shape of the distal end portion 29 ofthe waveguide 14 will expand to a greater magnitude when compared to theinside diameter or shape of the cavity 114 to establish an interferencefit therebetween as illustrated in FIG. 2A. The heat or thermal energymay be applied to the waveguide 28 by a radio frequency (RF) inductioncoil 120 mounted about the waveguide 28 adjacent the distal end portion29. In other embodiments, a resistive thermoelectric heat element 130may be employed. See FIG. 2B. Heat is applied until a sufficientinterference fit is established between the proximal end portion 112 ofthe surgical tool 100 and the distal end portion 29 of the waveguide 28.Thereafter, the heat applicator 120, 130 must continue to be energizedto maintain the interference fit throughout use. After the surgicalprocedure has been completed, the heat applicator 120, 130 may bede-energized. Once the temperature of the proximal end portion 29 of thewaveguide 28 returns to the approximate temperature of the proximal end114 of the surgical tool 100, the surgical tool may be detached from thewaveguide 28.

In the embodiment of FIG. 3, the distal end portion 29′ of the waveguide28′ has a portion 140 that is fabricated from material that has a highcoefficient of thermal expansion. For example, the portion 140 may befabricated from, for example, aluminum, while the remaining portion ofthe waveguide 28′ may be fabricated from steel. At normal roomtemperature (i.e., in an unheated state), the portion 140 may have thesame diameter or other parametrical shape as the distal end portion 29′of the waveguide 28′ to enable the portions 29′, 140 to be inserted intothe cavity 114′ in the proximal end portion 112′ of the surgical tool100′. Thus, a predetermined amount of clearance “C” is provided betweenthe portion 140 and the wall of the cavity 114′, prior to theapplication of heat or thermal energy to the distal end portion 29′ bythe heat applicator 120 or 130 (whichever the case may be). To couplethe surgical tool 100′ to the waveguide 28′, the heat applicator 120 or130 is energized to cause portion 140 to expand at a greater rate thanthe distal end portion 112′ of the surgical tool 100′ to create aninterference fit therebetween. See FIG. 3A.

FIG. 3B illustrates an alternative embodiment wherein a cavity 114″ isprovided in the distal end 29″ of the waveguide 28″ and the proximal endportion 112″ of the surgical tool 100″ is sized to be received withinthe cavity 114″. In this embodiment, the distal end 29″ of the waveguide28″ is fabricated from a first material 15″ that has first coefficientof thermal expansion (CTE1) and the proximal end portion 112″ of thesurgical tool 100″ is fabricated from a second material 103″ that has asecond coefficient of thermal expansion (CTE2) that is greater than thefirst coefficient of thermal expansion. Thus:

CET2>CET1

To couple the surgical tool 100″ to the waveguide 28″, the clinicianpositions the proximal end portion 112″ of the surgical tool 100″ in thecavity 114″ in the distal end portion 29″ of the waveguide 28″ asillustrated in FIG. 3B. Thermal energy (i.e., heat) is then applied tothe proximal end portion 112″ of the surgical tool 100″ to increase theoutside diameter or parametrical shape of the proximal end portion 112″through thermal expansion. Because CTE1<CTE2, the outer diameter orparametrical shape of the proximal end portion 112″ of the surgical tool100″ will expand at a greater magnitude when compared to the insidediameter or shape of the cavity 114″ to establish an interference fittherebetween. The heat or thermal energy may be applied to the proximalend portion 112″ of the surgical tool 100″ by a heat applicator 120which may comprise a radio frequency (RF) induction coil or resistiveheater 120″ mounted on the proximal end portion 112″. Power may besupplied thereto from the handpiece through appropriate connections. Forexample, the heating element 120″ may be mounted on the surgical tool100″ and, when the proximal end portion 112″ of the surgical tool 100″is inserted into the cavity 114″, the heat applicator 120″ may becoupled to wires (not shown) protruding from the handpiece to supplypower to the heat applicator 120″. Heat is applied until a sufficientinterference fit is established between the proximal end portion 112″ ofthe surgical tool 100″ and the distal end portion 29″ of the waveguide28″. Thereafter, the heat applicator 120 may be de-energized and/orremoved and the system may be used. Once the temperature of the proximalend portion 112″ of the surgical tool 100″ returns to the approximatetemperature of the distal end portion 29″ of the waveguide 28″, thesurgical tool 100″ may be detached from the waveguide 28″.

FIGS. 4-6 illustrate use of another coupling arrangement 310 of variousembodiments of the present invention for removably coupling a reusablesurgical tool 300 to a waveguide 228 of a handpiece 216 that is similarin construction and operation as the aforementioned handpiece 16 exceptfor the differences noted below. In some embodiments, for example, thedistal end 229 of the waveguide 228 may be tapered or frusto-conicallyshaped for receipt within a complementary-shaped cavity 314 provided ina proximal end portion 312 of the surgical tool 300. In this embodiment,the surgical tool 300 includes a housing or shroud portion 320 thatsupports the distal end portion 312 therein. In various embodiments, thedistal end portion 312 may be supported within a mount 26 thatfacilitates acoustic excitement of the distal end portion 312 relativeto the shroud 320. As can be seen in FIGS. 5 and 6, the shroud 320 has acavity 330 therein for receiving the distal end portion 218 of thehandpiece 216 therein. Shroud 320 further has an axial passage 332 toenable the waveguide 228 to extend therethrough into engagement with theproximal end portion 312 of the surgical tool 300. As can be furtherseen in FIGS. 4-6, the distal end portion 218 of the handpiece 216 has atapered portion 220 formed thereon. When the distal end portion 218 isreceived within the cavity 330 of the shroud 320, the tapered portion220 coincides with at least one selectively expandable latch member 350mounted in the shroud 320. The latch member(s) 350 may be fabricatedfrom, for example, a shape memory alloy (SMA) and be coupled tocorresponding tool contact(s) 352 mounted within the shroud 320. Forexample, a latch member 350 may be fabricated in the shape of a ring ora hoop from NiTi (Nickel—Titanium), CuZnAl, CuAlNi, etc. and be coupledto contact 352 by contact strip or strips 354. As can also be seen inFIGS. 4-6, an activation contact 230 is mounted in the distal endportion 218 of the handpiece 216. In various embodiments, the activationcontact 230 may comprise an annular ring or ring segment(s) formed fromelectrically conductive material (e.g., berillium copper) and which isin electrical communication (e.g., wired) to a source of electricalpower 240. The source of electrical power 240 may comprise, for example,a battery or a source of alternating current and may be integrated withthe aforementioned generator arrangement.

FIGS. 5 and 6 illustrate a method of coupling of the surgical tool 300to the waveguide 228 of the handpiece 216. To initiate the couplingprocess, the distal end portion 218 of the handpiece is inserted intothe cavity 330 in the housing 320 of the surgical tool 300 as shown inFIG. 5 such that activation contact 230 makes electrical contact withtool contact 352 to thereby permit electrical current (actuation signal)to energize the latch member(s) 350. In various embodiments, a switch244 may be provided in the electric line/wire 242 coupling the actuationcontact 230 to the source of electrical power 240. The switch 244 may,for example, be located on the handpiece or the generator. Thus, whenthe surgical tool 300 is coupled to the waveguide 228 as shown in FIG.5, and the switch 244 is activated, the latch 350 will be energized andstart to expand against the tapered portion 220. Those of ordinary skillin the art will appreciate that the engagement of the latch 350 with thetapered portion 220 causes the tool 300 to be pulled into retainingengagement with the waveguide 228 to achieve an acoustically sufficientconnection between the distal end portion 229 of the waveguide 228 andthe proximal end portion 312 of the surgical tool 300. See FIG. 6.

FIGS. 7-12 illustrate another coupling arrangement 510 of variousembodiments of the present invention for removably coupling a reusablesurgical tool 500 to a waveguide 428 of a handpiece 416 that is similarin construction and operation as the aforementioned handpiece 216 exceptfor the differences noted below. In this embodiment, at least one, andpreferably four, contact tabs 450 protrude out of the distal end 418 ofthe handpiece as shown in FIGS. 7 and 8. One or more of the contact tabs450 are wired to a source of electrical energy 240. As with the otherembodiments, a switch 244 may be provided to control the flow of currentfrom the source 240 to the contact tabs 450. The tool 500 has a toolshroud 520 that has corresponding tab slots 570 therein that are adaptedto receive a corresponding one of the contact tabs 450 to enable theshroud 520 to be slid onto the handpiece 416 to the position shown inFIG. 11. Thereafter, the clinician rotates the shroud 520 relative tothe handpiece 416 to cause the contact tabs 450 to each be received in acorresponding locking pocket 572 at the end of each slot 570. Anelectrical contact 574 may be positioned within or adjacent to eachlocking pocket 572 such that it makes electrical contact with thecorresponding contact tab 450 when seated within the locking pocket 572.The electrical contact 574 is in electrical communication with acorresponding one or more expandable latch member segments 550 supportedwithin the shroud 520. The latch member segments 550 are located suchthat when the tool 500 is seated onto the handpiece and the contact tabs450 are received in their respect lock pockets 572, the latch membersegments 550 are positioned to engage the tapered position 420 of thehandpiece 416.

To initiate the coupling process, the distal end portion 418 of thehandpiece is inserted into the cavity 530 in the shroud 520 of thesurgical tool 500 as shown in FIG. 11 such that the contact tabs 450 arereceived in their corresponding slots 570, the clinician rotates thehandpiece 416 relative to the surgical tool 500 to cause the contacttabs 450 to be seated in their corresponding locking pockets 572 and arein contact with the corresponding electrical contact 574 therein. If theswitch 244 is closed, electrical current is then permitted to flowthrough the electric contacts 574 to the expandable latch membersegments 550. As current flows to the expandable latch member segments550, the latch member segments 550 expand and pull the proximal end 512of the tool 500 into retaining engagement with the distal end 429 of thewaveguide 428.

FIGS. 13 and 14 illustrate another coupling arrangement 110′ of variousembodiments of the present invention for permanently coupling a surgicaltool 100 to a waveguide 28 of a handpiece 16. In this embodiment, thedistal end 29 of the waveguide 28 is sized to be received within acavity 114 in proximal end portion 114 of the surgical tool 100.Positioned within the cavity 114 is some meltable alloy material 115. Invarious embodiments, the meltable alloy material may comprise, forexample, copper-aluminum. In this embodiment, the clinician inserts thedistal end 29 of the waveguide 28 into the cavity 114 such that itcontacts the meltable alloy material 115. The clinician then operatesthe generator 12 to provide the waveguide 28 with a sufficient powerburst that is sufficient in magnitude and duration to cause the meltablealloy material 115 to weld the waveguide 28 to the tool 100. Asillustrated in FIG. 14, once welding is complete, the clinician reducesthe power to the normal operating magnitude. For example, normal powermagnitude may be 5 watts. To cause the meltable material 115 tosufficiently weld the waveguide 28 to the tool 100, the clinician mayhave to increase the power to, for example, 50 watts, for approximately5 seconds (time). The magnitude and duration of such increase may bedependent upon the type of meltable material 115 employed and thetransducer arrangement. In each case, however, the magnitude andduration of the power increase should be less than a magnitude andduration that would ultimately result in damage to the transducers orother components of the system.

Another coupling arrangement 710 is illustrated in FIGS. 15-20 forremovably coupling a reusable surgical tool 700 to a waveguide 628 of ahandpiece 616 that is similar in construction and operation as theaforementioned handpiece 16 except for the differences noted below. Forexample, the distal end 629 of the waveguide 628 may have afrusto-conically shaped cavity 630 therein for receiving acomplementary-shaped proximal end portion 712 of a surgical tool 700. Inthis embodiment, the surgical tool 700 includes a shroud 720 thatsupports the proximal end portion 712 therein. In various embodiments,the shroud 720 may be fabricated from, for example, Titanium 64 andproximal end portion 712 may be supported within a mount 26 thatfacilitates acoustically-generated movement of the proximal end portion712 relative to the shroud 720. As can be seen in FIGS. 15 and 16, theshroud 720 has an annular cavity 730 therein for receiving the distalend portion 618 of the handpiece 616 therein. Shroud 720 further has anaxial passage 732 to enable the waveguide 628 to extend therethroughinto engagement with the proximal end portion 712 of the surgical tool700.

As illustrated in FIGS. 15 and 16, the distal end 618 of the handpiece616 movably supports a release ring 640 that has diametrically opposingstem portions 642, 644 that extend through corresponding slots 646, 648,respectively in the distal end portion 618 of the handpiece 616. Thepurpose of the release ring 640 will be explained in further detailbelow. As can also be seen in FIGS. 15 and 16, the distal end portion629 of the waveguide 628 is also fitted with an annular groove 650 thatis configured to receive a locking ring 652 therein. Locking ring 652may be fabricated from a shape memory alloy (SMA) such as, for example,NiTi (Nickel—Titanium), CuZnAl, CuAlNi, etc. Locking ring 652 may alsobe supported in at least two, and preferably four, heat generating andcooling units 660 that are pivotally pinned by corresponding pins 661 orare otherwise pivotally coupled to the wall 619 of the distal end of thehandpiece 616.

FIGS. 15-18 illustrate one form of a heat generating/cooling unit 660 ofan embodiment of the present invention. In various embodiments, eachheat generating/cooling unit 660 has a body portion 663 that may befabricated from, for example, aluminum or engineered plastics such aspolycarbonate, and be configured with an upper chamber area 664 andlower chamber area 666 therein that are separated by a wall 668 that hasa fluid return passage 670 therethrough. The outer perimeter has aretention ledge 672 formed thereon for retaining engagement with alocking protrusion or protrusions 740 (FIGS. 19 and 20) formed in theshroud 720 of the surgical tool 700 as will be further discussed below.A return opening bar 676 slidably extends through a passage 675 in thebody portion 663 defined by a sponge member 680 and the wall 668. Thesponge member 680 may be supported on another wall portion 682 as shown.Return opening bar 676 has a hole 678 therethrough that may be coaxiallyaligned with the fluid return passage 670 to enable fluid/vapor to passbetween the lower chamber 666 and the upper chamber 664. A bellows orwiper arrangement 684 may be provided in the upper chamber 664 forsliding engagement with the return opening bar 676 such that the bellows684 serves to seal off the passage 675 when the return opening bar 676has not been axially advanced into the upper chamber 664. Aheating/cooling medium 686 is provided in the lower chamber 666. Invarious embodiments, the heating/cooling medium 686 may comprise, forexample, a liquid that has a relatively low boiling point such asacetone.

A method for coupling a surgical tool 700 to a handpiece 616 will now bedescribed. FIG. 15 illustrates the positions of various components inthe handpiece 616 and the surgical tool 700 prior to insertion of thedistal end 618 of the handpiece into the shroud 720 of the surgical tool700. To commence the coupling process, the clinician inserts the distalend 618 of the handpiece 616 into the shroud 720 of the surgical tool700. See FIG. 16. At this point, the handpiece 616 and the surgical tool720 are essentially at room temperature. As the distal end of thehandpiece 618 enters the annular cavity 730 in the shroud 720, a poweractivation switch 690 mounted in the distal end portion 618 of thehandpiece 616 permits current to flow to the generator to cause thetransducers to be energized. In various embodiments, when the waveguide628 and the locking ring 652 supported thereon are at room (neutral)temperature, the locking ring 652 is contracted about the distal end ofthe waveguide 628 such that the cavity 630 therein will not fully acceptthe frusto-conically shaped proximal end 712 of the surgical tool 700.However, activation of the transducers causes the waveguide 628 to heatthe locking ring 652 causing it to expand to a point wherein theproximal end 712 of the surgical tool may be properly seated within thecavity 630. As the coupling process is initiated, the locking protrusion740 (FIG. 19) pivots each of the heat generating/cooling units 660 abouttheir respective pins into tight contact with the vibrating waveguide628 to facilitate the generation of heat around the locking ring. Thispivoting action is represented by arrows “A” in FIG. 16. When theproximal end 712 is completely seated within the cavity 630, the lockingprotrusion 740 snaps over the retention ledge 672 on the heatgenerating/cooling units 660 as shown in FIGS. 17 and 20. Those ofordinary skill in the art will appreciate that as the locking protrusion740 snaps over the retention ledges 672, the clinician may be providedwith tactile feedback and/or an audible click to indicate that thesurgical tool 700 has been properly advanced to the coupled position.The locking protrusion 740 enables the heat generating/cooling units topivot back to a neutral or unpivoted position wherein the lockingprotrusion 740 and the retention ledges still retain the surgical tool700 in the coupled position. When in the coupled position as shown inFIGS. 17 and 20, the distal end 721 of the shroud 720 activates powerdeactivation switch 689 which stops the flow of electrical current tothe transducers. The coupling procedure is now complete. The clinicianis now free to use the system. It will be further understood thatfurther operation of the transducers will cause the locking ring 652 toonce again expand; however, the locking protrusion 740 and retentionledges 672 serve to maintain the coupled engagement between the surgicaltool 700 and the handpiece 616.

Turning to FIGS. 18-20, it is desirable for the locking ring 652 to behot during the initial coupling process to enable the proximal 712 endof the tool 700 to be inserted into the cavity 630. During that heatingprocess, the liquid 686 resides in the sponge 680 and in the upperchamber 664. As can be seen in FIG. 20, when in the locked position, theheat generating cooling units 660 are adjacent a heat sink ring 692mounted within the wall of the shroud 720. Such arrangement assists indissipating the heat from the heat generating/cooling units 660. Whenthe locking protrusion 740 is in the retention position (FIGS. 17 and20) and the transducers have been deactivated, it is desirable for thelocking ring 652 to cool to further secure the distal end of thewaveguide 629 to the proximal end 712 of the tool 700. Advancement ofthe locking protrusion 740 to the locked position biases the returnopening bar 676 to cause hole 678 in the bar 676 to be aligned with thereturn passage 670 to enable the fluid 686 in the upper chamber 664 toflow into the lower chamber 666. As the liquid 686 flows out of theupper chamber 684 it contacts the hot lower chamber 666 surfaces andevaporates to cool those surfaces and ultimately the locking ring 652.

To detach the surgical tool from the handpiece 616, the clinician movesthe release ring 640 to activate the activation switch 689 or contactwhich causes the transducers to start the vibration process and beginthe heating cycle. As the heat generating/cooling units 660 begin toheat up, the locking ring 652 begins to expand to enable the clinicianto pull the surgical tool apart from the handpiece 616. When the partshave been separated, the power activation switch discontinues the powerto the transducers after the power actuation switch is no longeractivated by the distal end 721 of the tool shroud 720. Those ofordinary skill in the art will appreciate that a variety of knownswitches and switching arrangements, microprocessor controlled contacts,etc. may be used to activate and deactivate the transducers during thetool coupling process without departing from the spirit and scope of thepresent invention. For example, the power activation switches maycomprise proximity sensing switches or contacts that are coupled to amicroprocessor housed in or mounted adjacent to the generator.

FIGS. 21-23 illustrate another surgical tool system 800 embodiment ofthe present invention that includes a generator 12 and a handpiece 816that is substantially similar in design and construction as handpiece 16described above, except for the differences noted below. For example,the distal end 829 of the waveguide 826 is selectively radiallyexpandable to enable the distal end 829 to be effectively coupled to theproximal end 912 of the surgical tool 900. As can be most particularlyseen in FIGS. 22 and 23, the distal end 829 of the waveguide 826 has twoopposed lugs 830 that are shaped to retainingly engage a cavity 930 inthe proximal end 912 of the surgical tool 900. The cavity 930 may beprovided with tapered walls 932 such that when the lugs 830 are insertedin cavity 930 and then moved radially (arrows “R”), the lugs 830 serveto pull the tool 900 into retaining engagement with the distal end 829of the waveguide 826 as shown in FIG. 23. In various embodiments, thewaveguide 826 may be fabricated from, for example, aluminum 7075-T6.

Various embodiments may include an axially movable actuator rod 850 thatis movably supported within a slot 840 in the waveguide 826. Theactuator rod 850 may be fabricated from, for example, ultem, PEI andhave a distal end 852 that is sized to extend between lugs 830 and, whenadvanced distally between the lugs 830, causes the lugs 830 to moveradially. As can be seen in FIG. 21, the actuator rod 850 may have aradially extending portion 854 that extends through slots 842 and 817 inthe waveguide 826 and handpiece 816, respectively. The radiallyextending portion 854 may terminate in a button portion 856 thatfacilitates actuation of the rod 850 by the clinician.

Thus, to couple the surgical tool 900 to the handpiece 816, theclinician inserts the lugs 830 into the cavity 930 while the actuatorrod 850 is in an unactuated position (FIG. 22). Once the lugs 830 areinserted into the cavity 930, the clinician may slide the button portion856 in the distal direction “DD” to cause the distal end 852 of theactuator rod 850 to axially move between the lugs 830 to cause the tomove radially and engage the tapered walls of the cavity 930 (FIG. 23).

Various devices disclosed herein can be designed to be disposed of aftera single use, or they can be designed to be used multiple times. Ineither case, however, the device may be reconditioned for reuse after atleast one use. Reconditioning can include any combination of the stepsof disassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

Preferably, the various embodiments described herein will be processedbefore surgery. First, a new or used instrument is obtained and ifnecessary cleaned. The instrument can then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic bag. The container and instrument are thenplaced in a field of radiation that can penetrate the container, such asgamma radiation, x-rays, or high-energy electrons. The radiation killsbacteria on the instrument and in the container. The sterilizedinstrument can then be stored in the sterile container. The sealedcontainer keeps the instrument sterile until it is opened in the medicalfacility.

It is preferred that the device is sterilized. This can be done by anynumber of ways known to those skilled in the art including beta or gammaradiation, ethylene oxide or steam.

Although various embodiments have been described herein, manymodifications and variations to those embodiments may be implemented.For example, different types of end effectors may be employed. Also,where materials are disclosed for certain components, other materialsmay be used. The foregoing description and following claims are intendedto cover all such modification and variations.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdoes not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

1-15. (canceled)
 16. An ultrasonic surgical instrument, comprising: anultrasonic transducer; an ultrasonic end effector; and a waveguideconfigured to transmit ultrasonic energy generated by the ultrasonictransducer to the ultrasonic end effector, wherein the waveguideincludes an attachment portion selectively expandable into anacoustically coupled retaining engagement with the ultrasonic endeffector.
 17. The surgical instrument of claim 16, further comprising anactuator movable between a first position wherein the attachment portionis unexpanded and a second position wherein the attachment portion isexpanded.
 18. The surgical instrument of claim 16, wherein theattachment portion is selectively radially expandable from an unexpandedconfiguration to an expanded configuration.
 19. The surgical instrumentof claim 16, further comprising a housing operably supporting theultrasonic transducer.
 20. The surgical instrument of claim 16, whereinthe ultrasonic end effector comprises an ultrasonic blade.
 21. Anultrasonic surgical instrument, comprising: an ultrasonic transducer; anultrasonic end effector; a waveguide configured to transmit ultrasonicenergy generated by the ultrasonic transducer to the ultrasonic endeffector; and an engagement mechanism selectively expandable totransition the waveguide into an acoustically coupled retainingengagement with the ultrasonic end effector.
 22. The surgical instrumentof claim 21, further comprising an actuator movable between a firstposition wherein the engagement mechanism is unexpanded and a secondposition wherein the engagement mechanism is expanded.
 23. The surgicalinstrument of claim 21, wherein the engagement mechanism is selectivelyradially expandable from an unexpanded configuration to an expandedconfiguration.
 24. The surgical instrument of claim 21, furthercomprising a housing operably supporting the ultrasonic transducer. 25.The surgical instrument of claim 21, wherein the ultrasonic end effectorcomprises an ultrasonic blade.
 26. An ultrasonic surgical instrument,comprising: an ultrasonic transducer; an ultrasonic end effector; awaveguide configured to transmit ultrasonic energy generated by theultrasonic transducer to the ultrasonic end effector; and an engagementmechanism selectively movable from a first configuration to a secondconfiguration to transition the waveguide into an acoustically coupledretaining engagement with the ultrasonic end effector, wherein thesecond configuration is greater in size than the first configuration.27. The surgical instrument of claim 26, further comprising an actuatormovable between a first position wherein the engagement mechanism is inthe first configuration and a second position wherein the engagementmechanism in the second configuration.
 28. The surgical instrument ofclaim 26, wherein the engagement mechanism is selectively radiallyexpandable from an unexpanded configuration to an expandedconfiguration.
 29. The surgical instrument of claim 26, furthercomprising a housing operably supporting the ultrasonic transducer. 30.The surgical instrument of claim 26, wherein the ultrasonic end effectorcomprises an ultrasonic blade.
 31. An ultrasonic surgical instrument,comprising: an ultrasonic transducer; an ultrasonic end effector; awaveguide configured to transmit ultrasonic energy generated by theultrasonic transducer to the ultrasonic end effector, wherein thewaveguide defines a central axis extending longitudinally; and anengagement mechanism selectively movable in a direction away from thecentral axis to transition the waveguide into an acoustically coupledretaining engagement with the ultrasonic end effector.
 32. The surgicalinstrument of claim 31, further comprising an actuator movable from afirst position to a second position to cause the engagement mechanism tomove away from the central axis.
 33. The surgical instrument of claim31, further comprising a housing operably supporting the ultrasonictransducer.
 34. The surgical instrument of claim 31, wherein theultrasonic end effector comprises an ultrasonic blade.